TANK001 TOYOTA LANDCRUISER 76 Series

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1 INSTALLATION GUIDE TANK001 TOYOTA LANDCRUISER 76 Series Ironman 4x4 Long Range Fuel Tank fits to a Toyota 76 Series Landcruiser up to 11/2012. It will take about 4 hours to install. IMPORTANT: Please note that it is the installer s responsibility to ensure that the inside of the fuel tank is completely clean and free from foreign matter prior to installation. IMPORTANT: Fuel Tank installations should only be done by a qualified person and it is the responsibility of this person to ensure correct fitment and to ensure the tank is free from fuel leaks.

2 1. Before installation check fuel tank application is compatible with your vehicle. 2. Remove tow bar from vehicle if applicable. 3. Remove plastic mud guard liner from right hand rear to allow access to fuel filler hose. 4 Disconnect fuel filler and fast fill breather hose. 5. Remove check valve hose from tank. 6. Unclip and disconnect fuel sender wires. Page 2 of 9

3 7. Disconnect fuel pick up and return lines at the right hand side front of fuel tank. 8. Remove fuel tank. 9. Remove check valve and hose and store in a safe place for later refitment. 10. Remove fuel tank support strap brackets. 11. Bend bracket on cross member up and forwards as shown to allow clearance for new tank. Page 3 of 9

4 12. Cut four mounts from floor ribs. Rust proof and de burr. 13. Unclip wiring loom form rear cross member to allow access to the body seam below loom. 14. Using a hammer, bend seam backwards about 5mm to allow clearance for tank. 15. Bend pick up and return lines under cross member as shown. Page 4 of 9

5 16. Fuel sender will need to be modified as follows. A. Carefully straighten out the four bends as shown. The reshaped unit should be slightly off vertical. Be careful not to damage electrical wire attached to low level arm. Test fit sender to tank and make sure float does not hit the bottom. B. Fuel pick up assembly will have to be modified as follows. Note: Extreme care must be taken not to kink or damage pipes during this process. Page 5 of 9

6 C. Remove filter from fuel pick up and carefully support pick up assembly in a vice. Straighten lower bend as shown. PUSH THIS WAY BOTTOM SECTION NOW STRAIGHT AFTER BEFORE D. Carefully support upper section of pick up assembly in vice, and bend towards white line as shown. UP TO THIS LINE PUSH THIS WAY BEFORE AFTER Page 6 of 9

7 E. Carefully support lower section of fuel pick up in vice and bend as shown, to allow end of pick up to point slightly towards bottom of fuel tank once installed. PUSH THIS WAY F. Carefully support pipes in vice as shown and bend pick up assembly in direction shown in photograph to allow pipes to sit closer to top of fuel tank once installed. PUSH THIS WAY 17. Install fuel sending into new tank making sure the float clears the bottom of the tank. 18. Refit filter to fuel pick up and install assembly to fuel tank making sure the pick up is close to but not touching the bottom of the fuel tank. Page 7 of 9

8 19. Cut check valve hose (Removed in earlier step) in half and fit to fuel tank as shown. DISREGARD THE CUT OFF SECTION OF HOSE 20. Lift fuel tank into position in vehicle and secure front mount to round cross member between upper shock absorber mounts. Do NOT tighten. 21. Raise and support rear of fuel tank so that mounting points are pushed against corner gussets of chassis. Centralise fuel tank and drill holes through chassis on each side using mounting holes in fuel tank as a guide. Page 8 of 9

9 22. Rust proof holes drilled in previous step and secure rear mounts to chassis using bolts, washers and nuts supplied. Tighten all mounting nuts and bolts. 23. Cut fuel pick up and return hoses to required length and reconnect. 24. Cut fuel filler and fast fill breather hoses to required length and refit. 25. Check drain plug in bottom of fuel tank is tight. 26. Fill fuel tank and check operation of sender. 27. Start vehicle and check for leaks and refit plastic mud guard liner. Page 9 of 9

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